Visor assembly for a cap

ABSTRACT

A cap assembly is disclosed herein. The cap assembly includes a crown assembly and a visor assembly. The crown assembly includes a crown and a sweatband. The visor assembly include a visor and a connector. The visor has a concave edge. The connector extends from proximate the concave edge to between the sweatband and the crown.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional patentapplication Ser. No. 62/768,004 entitled “Visor Assembly for Caps” filedon Nov. 15, 2018. The foregoing application is hereby incorporated byreference in its entirety.

TECHNICAL FIELD

The present disclosure generally pertains to caps. More particularlythis application is directed toward a visor assembly for a cap.

BACKGROUND

Caps are often purchased for their subtle differences in appearance andpersonal aesthetic appeal. Caps can come in a variety of styles, colors,and patterns. However, with the current available caps, there arelimitations on the aesthetic possibilities that stem from manufacturinglimitations.

The present disclosure is directed toward improvements in the art.

SUMMARY

A visor assembly for a cap is disclosed herein. The visor assemblyincludes a visor having a visor top surface, a visor bottom surface, aconcave edge extending between the visor top surface and the visorbottom surface. The concave edge has a first end, and a second endopposite the first end. The visor further includes a front edgeextending from adjacent the first end to adjacent the second end. Thevisor assembly further includes a connector. The connector has aconnector top portion positioned adjacent to the visor top surface. Theconnector top portion has a connector top portion edge located proximateto the concave edge. The connector top portion edge extends fromproximate the first end to proximate the second end. The connectorfurther includes a connector bottom portion positioned adjacent to thevisor bottom surface and spaced from the connector top portion. Theconnector bottom portion has a connector bottom portion edge positionedproximate to the concave edge. The connector bottom portion edge extendsfrom proximate the first end to proximate the second end. The connectorfurther includes a connector back portion extending from proximate theconcave edge and away from the front edge.

BRIEF DESCRIPTION OF THE FIGURES

The details of embodiments of the present disclosure, both as to theirstructure and operation, may be gleaned in part by study of theaccompanying drawings, in which like reference numerals refer to likeparts, and in which:

FIG. 1 is a front view of an exemplary cap assembly;

FIG. 2 is a bottom view of the cap assembly from FIG. 1;

FIG. 3 is a cross section view of a portion of the cap assembly fromFIG. 1 along line from FIG. 2;

FIG. 4 is a top view of the visor from FIG. 1 isolated away from the capassembly;

FIG. 5 is a top view of an exemplary embodiment of a visor;

FIG. 6 is a top view of an exemplary embodiment of a visor;

FIG. 7 is a top view of an exemplary embodiment of a visor;

FIG. 8 is a top view of the visor assembly from FIG. 1;

FIG. 9 is a sectional view of the visor assembly shown in FIG. 8 alongline IX-IX from FIG. 8;

FIG. 10 is a sectional view of an exemplary visor assembly;

FIG. 11 is a sectional view of an exemplary visor assembly;

FIG. 12 is a sectional view of an exemplary visor assembly;

FIG. 13 is a sectional view of an exemplary visor assembly;

FIG. 14 is a sectional view of an exemplary visor assembly;

FIG. 15 is a sectional view of an exemplary cap assembly;

FIG. 16 is a top view of an exemplary embodiment of a visor;

FIG. 17 is a top view of an exemplary embodiment of a visor;

FIG. 18 is a sectional view of an exemplary visor assembly;

FIG. 19 is a sectional view of an exemplary visor assembly;

FIG. 20 is a sectional view of an exemplary visor assembly; and

FIG. 21 is a sectional view of an exemplary visor assembly.

DETAILED DESCRIPTION

The detailed description set forth below, in connection with theaccompanying drawings, is intended as a description of variousembodiments and is not intended to represent the only embodiments inwhich the disclosure may be practiced. The detailed description includesspecific details for the purpose of providing a thorough understandingof the embodiments. However, it will be apparent to those skilled in theart that embodiments of the invention can be practiced without thesespecific details. In some instances, well-known structures andcomponents are shown in simplified form for brevity of description.

FIG. 1 is a front view of an exemplary cap assembly. Some of thefeatures and surfaces have been left out, spaced apart, and/orexaggerated (here and in other figures) for visual clarity and ease ofexplanation. A cap assembly 100 (sometimes referred to as a cap or hat)includes a crown assembly 400 and a visor assembly 200. The crownassembly 400 may be sized to fit a person's head similar to a typicalbaseball cap. The visor assembly 200 can include a connector 300 and avisor 210. The visor 210 may be shaped similar to a visor of typicalbaseball cap and can be disposed proximate the base of the crownassembly 400.

FIG. 2 is a bottom view of the cap assembly from FIG. 1. The crownassembly 400 includes a crown 410 and sweatband 450. The sweatband 450can be sewn to the crown 410 adjacent to the base of the crown. Thevisor 210 can extend from adjacent to the connector 300 to away from thecrown assembly 400. A portion of the connector 300 can be positionedbetween the visor 210 and the crown assembly 400. In an embodiment, theconnector 300 partially covers the visor 210. In an embodiment themajority of the visor 210 is exposed and not covered by the connector300.

FIG. 3 is a cross section view of a portion the cap assembly from FIG. 1along line in FIG. 2. Components of the cap assembly 100 are shownschematically for ease of drafting and visual clarity. Some componentsare visually represented spaced apart (here and in other figures), butcan make contact with one another when assembled together as visorassemblies and cap assemblies. The connector 300 is shown in greaterdetail on FIG. 9.

The visor 210 includes a visor top surface 220 disposed at the top faceof the visor 210, a concave edge 230 disposed proximate to the crownassembly 400 and the connector 300, a front edge 231 disposed oppositefrom the concave edge 230, and a visor bottom surface 240 disposed onthe bottom face of the visor 210. The connector 300 includes a connectortop portion 310, a connector bottom portion 320, a connector end portion350, and a connector back portion 340 (sometimes referred to as firstconnector back portion).

The connector top portion 310 can be positioned proximate to the visortop surface 220. In an embodiment the connector top portion 310 isoriented substantially parallel with the visor top surface 220. Theconnector top portion 310 can have a connector top portion edge 311. Theconnector top portion edge 311 can be positioned proximate to theconcave edge 230 of the visor 210.

The connector bottom portion 320 can be spaced from the connector topportion 310 and positioned proximate to the visor bottom surface 240. Inan embodiment the connector bottom portion 320 is oriented substantiallyparallel with the visor bottom surface 240. In an embodiment theconnector bottom portion 320 is oriented substantially parallel with theconnector top portion 310. The connector bottom portion 320 can have aconnector bottom portion edge 321. The connector bottom portion edge 321can be positioned proximate to the concave edge 230 of the visor 210. Inan embodiment the connector bottom portion edge 321 and the connectortop portion edge 311 are substantially equidistant from the concave edge230.

The connector end portion 350 can extend between the connector topportion 310 and the connector bottom portion 320. In an embodiment theconnector end portion 350 can extend from the connector top portion 310to the connector bottom portion 320. The connector end portion 350 canbe positioned proximate to the concave edge 230. The connector endportion 350 can extend substantially perpendicular between the connectortop portion 310 and the connector bottom portion 320.

The connector back portion 340 can extend from proximate the concaveedge 230 to adjacent the crown 410. In an embodiment the connector backportion 340 can extend from proximate the concave edge 230 to betweenthe sweatband 450 and the crown 410. The connector back portion 340 canextend from the connector end portion 350 and away from the front edge231. In an embodiment the connector back portion 340 can extendsubstantially perpendicular from the connector end portion 350.

Top adhesive 292 can be disposed between the visor top surface 220 andthe connector top portion 310. The top adhesive 292 can be used tocouple the connector top portion 310 to the visor top surface 220.Bottom adhesive 290 can be disposed between the visor bottom surface 240and the connector bottom portion 320. The bottom adhesive 290 can beused to couple the connector bottom portion 320 to the visor bottomsurface 240. Back adhesive 291 can be disposed between the concave edge230 and the connector 300. The back adhesive 291 can be used to couplethe connector 300 to the concave edge 230. The bottom adhesive 290, backadhesive 291, and the top adhesive 292 can comprise tape, glue, andother bonding adhesives.

The connector 300 maybe comprise of plastic, metal, composite, wood, andother materials that can be manufactured into the connector 300 shown.

A fastener 264 (sometimes referred to as a second fastener) can extendthrough the crown 410, the connector back portion 340, and the sweatband450. The fastener 264 can couple the connector back portion 340 to thecrown 410.

In an embodiment, the fastener 264 may be sewing thread. In otherexamples the fastener 264 can comprise other know fasteners such asmechanical fasteners, adhesives, heat or friction welding, laserbonding, or other fastening mechanisms.

FIG. 4 is a top view of the visor from FIG. 1 isolated away from the capassembly. The visor 210 includes the concave edge 230 and the front edge231. The concave edge 230 can have a first end 283 and a second end 284opposite the first end 283. The visor 210 can have a first corner 281and a second corner 282. The first end 283 and the second end 284 can beadjacent to the first corner 281 and the second corner 282 respectively.The concave edge 230 can extend from proximate the first corner 281 toproximate the second corner 282. The front edge 231 can extend fromproximate the first end 283 of the concave edge 230 to proximate thesecond end 284 of the concave edge. The front edge 231 can be convexwith respect to the visor 210. The front edge 231, the concave edge 230,the first corner 281, and the second corner 282 can define the shape ofthe visor 210.

FIG. 5 is a top view of an exemplary embodiment of a visor. Structuresand features previously described in connection with earlier describedembodiments may not be repeated here with the understanding that, whenappropriate, that previous description applies to the embodimentdepicted in FIG. 5 and following figures. Additionally, the emphasis inthe following descriptions is on variations of previously introducedfeatures or elements. Also, some reference numbers for previouslydescripted features are omitted from the drawing to provide additionalvisual clarity and readability of the drawing.

Where the drawing includes multiple instances of the same feature, forexample fastening feature 252, the reference number is only shown inconnection with one instance of the feature to improve the clarity andreadability of the drawing. This is also true in other drawings whichinclude multiple instances of the same feature.

A visor 212 can include a fastening feature 252. In an embodiment therecan be a plurality of fastening features 252 spaced apart and can bespace from and positioned proximately along the concave edge 230. Inother words, the fastening features 252 are positioned to contour theconcave edge 230. The fastening features 252 can be positioned at thefirst corner 281 and the second corner 282.

In an embodiment the fastening features 252 extend through the visor 212and can be apertures. In an example the fastening features 252 extendpart way through the visor 212 and can be depressions. The fasteningfeatures 252 can have a rectangular cross section with respect to thevisor top surface 220. In other examples the fastening features 252 canhave other cross-section shapes such as circular, elliptical,trapezoidal, triangular, or other combinations of curved and/or straightportions.

FIG. 6 is a top view of an exemplary embodiment of a visor. A visor 214can include a visor top surface 224 disposed at the top face of thevisor 214 and a fastening feature 254 extending along and proximate tothe concave edge 230. The fastening feature 254 can extend from thefront edge 231 proximate the first corner 281 to the front edge 231proximate the second corner 282. The fastening feature 254 cancontinuously contour the concave edge 230. The fastening feature 254 canbe a groove, depression, or channel.

FIG. 7 is a top view of an exemplary embodiment of a visor. A visor 216can include fastening features 256. The fastening features 256 can havevarying spacing between each other. The fastening features 256 can becircular shaped apertures through the visor 216.

FIG. 8 is a top view of the visor assembly from FIG. 1. The connectortop portion 310 can extend along the visor top surface 220 adjacent tothe concave edge 230 (shown on FIG. 4). The connector top portion 310can extend from the first corner 281 (shown on FIG. 4) to the secondcorner 282 (shown on FIG. 4) and can contour the concave edge 230 (shownin FIG. 4).

The connector top portion edge 311 can be positioned between the concaveedge 230 (shown in FIG. 4) and the front edge 231. The connector topportion edge 311 can extend from proximate the first corner 281 (shownon FIG. 4) to the second corner 282 (shown on FIG. 4) and can contourthe concave edge 230 (shown in FIG. 4).

The connector end portion 350 can extend from proximate the first corner281 (shown on FIG. 4) to the second corner 282 (shown on FIG. 4) and cancontour the concave edge 230 (shown in FIG. 4).

The connector back portion 340 can extend from proximate the firstcorner 281 (shown on FIG. 4) to the second corner 282 (shown on FIG. 4)and can contour the concave edge 230 (shown in FIG. 4).

FIG. 9 is a sectional view of the visor assembly shown in FIG. 8 alongline IX-IX from FIG. 8. The connector 300 from FIG. 3 is shown here withadditional detail. The connector 300 and adhesives 290, 291, 292 areshown spaced from the visor 210 to provide visual clarity of thedrawing. However the connector 300 contacts the adhesives 290, 291, 292,which contact the visor 210. Spaces shown between connectors and visorsin other figures may also be for visual clarity and connectors andvisors may be in contact with each other in the other figures.

The connector back portion 340 can be positioned substantiallyequidistant from the connector top portion 310 and the connector bottomportion 320. The connector back portion 340 can extend substantiallyperpendicular from the connector end portion 350 away from the concaveedge 230.

FIG. 10 is a sectional view of an exemplary visor assembly. A visorassembly 201 can include the visor 210 and the connector 300. In anembodiment the visor 210 and the connector 300 can contact each other.

The connector top portion 310 can be disposed adjacent the visor topsurface 220. The connector top portion 310 can be adjoined to the visortop surface 220 via top interface 272. The connector bottom portion 320can be disposed adjacent the visor bottom surface 240. The connectorbottom portion 320 can be adjoined to the visor bottom surface 240 viabottom interface 274. The connector end portion 350 can be disposedadjacent the concave edge 230. The connector 300 can be adjoined to theconcave edge 230 via back interface 273.

Interfaces 272, 273, 274 may each adjoin the connector 300 to the visor210 by ultrasonic welding, thermo-bonding, plastic welding, solventwelding, heat sealing, infrared welding, radio frequency welding,friction welding, induction welding, laser welding, or other bonding,welding, or connection methods.

In an example the connector 300 and the visor 210 can be one piece andmade of the same parent material.

FIG. 11 is a sectional view of an exemplary visor assembly. A visorassembly 202 can include the visor 214 and a connector 302. The visor214 includes the visor top surface 224 and a visor bottom surface 244.The connector 302 includes a connector top portion 312 that can bedisposed adjacent the visor top surface 224. The connector top portioncan include a connector top portion edge 313 and a connector topprotrusion 332 disposed adjacent the connector top portion edge 313. Theconnector top protrusion 332 extends from the connector top portion 312towards the connector bottom portion 322. In an example the connectortop protrusion 332 extends from the front edge 231 (shown on FIG. 6)proximate the first corner 281 (shown on FIG. 6) to the front edge 231proximate the second corner 282 (shown on FIG. 6) such that theconnector top protrusion 332 aligns with the fastening feature 254 ofthe visor 214. In an embodiment the connector top protrusion 332 extendsinto the fastening feature 254.

The visor 214 can include a fastening feature 253 at the visor bottomsurface 244, opposite from the fastening feature 254. The fasteningfeature 253 can extend along and proximate to the concave edge 230. Thefastening feature 253 can extend from the front edge 231 proximate thefirst corner 281 to the front edge 231 proximate the second corner 282.The fastening feature 253 can continuously contour the concave edge 230.The fastening feature 253 can be a groove, depression, or channel.

The connector 302 can include a connector bottom portion 322 that can bedisposed adjacent the visor bottom surface 244. The connector bottomportion 322 can include a connector bottom portion edge 323 and aconnector bottom protrusion 333 disposed adjacent the connector bottomportion edge 323. The connector bottom protrusion 333 extends from theconnector bottom portion 322 towards the connector top portion 312. Inan example the connector bottom protrusion 333 extends from the frontedge 231 (shown on FIG. 6) proximate the first corner 281 (shown on FIG.6) to the front edge 231 proximate the second corner 282 (shown on FIG.6) such that the connector bottom protrusion 333 aligns with thefastening feature 253 of the visor 214. In an embodiment the connectorbottom protrusion 333 extends into the fastening feature 253.

FIG. 12 is a sectional view of an exemplary visor assembly. A visorassembly 204 includes a visor 212 and a connector 304. The connector 304includes a connector top portion 314 that can include a connector topportion edge 315, and a connector top protrusion 334 disposed adjacentthe connector top portion edge 315. The connector top protrusion 334extends from the connector top portion 314 towards the connector bottomportion 324. In an example there are multiple connector top protrusions334 that may be located proximate to and along the connector top portionedge 315 such that the connector top protrusions 334 line up with thefastening features 252 of the visor 212. In an embodiment the connectortop protrusions 334 extends into the fastening feature 252. Theconnector top protrusion 334 can be shaped with a taper. The taperedshape of the connector top protrusion 334 can facilitate the mating ofthe visor 212 with the connector 304.

The connector 304 can include a connector bottom portion 324 that caninclude a connector bottom portion edge 325, and a connector bottomprotrusion 335 disposed adjacent the connector bottom portion edge 325.The connector bottom protrusion 335 extends from the connector bottomportion 324 towards the connector top portion 314. In an example thereare multiple connector bottom protrusions 335 that may be locatedproximate to and along the connector bottom portion edge 325 such thatthe connector bottom protrusions 335 line up with the fastening features252 of the visor 212. In an embodiment the connector bottom protrusions335 extends into the fastening feature 254. The connector bottomprotrusion 335 can be shaped with a taper. The tapered shape of theconnector bottom protrusion 335 can facilitate the mating of the visor212 with the connector 304.

FIG. 13 is a sectional view of an exemplary visor assembly. A visorassembly 206 can include the visor 216 and a connector 306. Theconnector 306 can include a connector top portion 316 disposed adjacentthe visor top surface 220. The connector top portion 316 can include aconnector top portion edge 317. The connector 306 can also include aconnector bottom portion 326 that is disposed adjacent the visor bottomsurface 240. The connector bottom portion 326 can include a connectorbottom portion edge 327.

The visor 216 can include the fastening feature 256 disposed proximateto the concave edge 230. The fastening feature 256 can extend throughthe visor 216. A mechanical fastener 295 can extend through theconnector top portion 316 proximate the connector top portion edge 317through the fastening feature 256 to through the connector bottomportion 326 proximate the connector bottom portion edge 327. Themechanical fastener 295 can be used to connect the connector 306 to thevisor 216. The mechanical fastener 295 may comprise rivets, eyelets,sewing thread, screws, grommets, plastic inserts, and other commonfasteners.

FIG. 14 is a sectional view of an exemplary visor assembly. A visorassembly 208 can includes a visor 210 and a connector 308. The connector308 can include two separate pieces, a connector top piece 351 and aconnector bottom piece 352. The connector top piece 351 can include aconnector top portion 318, a connector top portion edge 319, and a firstconnector back portion 348 (sometimes referred to as the connector backportion). Top adhesive 292 can be disposed between the visor top surface220 and the connector top portion 318. The top adhesive 292 can be usedto connect the connector top portion 318 to the visor top surface 220.The connector bottom piece 352 can include a connector bottom portion328, a connector bottom portion edge 329, and a second connector backportion 347 (sometimes referred to as the connector bottom portion).Bottom adhesive 290 can be disposed between the visor bottom surface 240and the connector bottom portion 328. The bottom adhesive 290 can beused to connect the connector bottom portion 328 to the visor bottomsurface 240. The top adhesive 292 and bottom adhesive 290 may comprisetape, glue, and other bonding adhesives. The first connector backportion 348 and the second connector back portion 347 may be disposedadjacent to each.

FIG. 15 is a sectional view of an exemplary cap assembly. A cap assembly101 can include the visor assembly 208 and the crown assembly 401. Thecrown assembly can include the crown 410 and a sweatband 451. Thesweatband 451 can be positioned proximate the base of the crown 410 at afirst location and extend to partially within the crown 410 at a secondlocation.

The first connector back portion 348 and the second connector backportion 347 can extend to and be positioned between the crown 410 andthe sweatband 451.

A first fastener 262 can extend through the crown 410, the connectorback portion 340, and the sweatband 450 at the first location. Thesecond fastener 264 can extend through the crown 410, the connector backportion 340, and the sweatband 450 at the second location. In anembodiment, the first fastener 262, and the second fastener 264 may besewing thread. In other examples the first fasteners 262 and secondfasteners 264 can comprise other know fasteners such as mechanicalfasteners, adhesives, heat or friction welding, laser bonding, or otherfastening mechanisms.

FIG. 16 is a top view of an exemplary embodiment of a visor. A visor 217can include a fastening feature 257. In an embodiment there can be aplurality of fastening features 257 spaced apart. The fastening features257 can be spaced from and positioned approximately along the concaveedge 230. In other words, the fastening features 257 are positioned tocontour the concave edge 230. The fastening features 257 can bepositioned at the first corner 281 and the second corner 282. In anembodiment there are seven fastening features 257. In other examplesthere can be one, two, three, four, five, six, eight, nine, ten, or morefastening features 257. In an embodiment the fastening features 257 canextend through the visor 217 as circular shaped apertures.

FIG. 17 is a top view of an exemplary embodiment of a visor. A visor 218can include the fastening features 257. The visor 214 can include avisor bottom surface 247 and a visor step 259 extending into the visor214 adjacent to the concave edge 230. The visor step 259 can extendalong the concave edge 230. The visor step 259 can extend from the frontedge 231 proximate the first corner 281 to the front edge 231 proximatethe second corner 282. The visor step 259 can continuously contour theconcave edge 230. The visor step 259 can be a groove, depression, orchannel.

FIG. 18 is a sectional view of an exemplary visor assembly. A visorassembly 203 can include the visor 217 and a connector 305. Theconnector 305 can include a connector top portion 618 disposed adjacentthe visor top surface 220. The connector top portion 319 can include aconnector top portion edge 619. The connector 306 can also include aconnector bottom portion 336 that is disposed adjacent the visor bottomsurface 240. The connector bottom portion 336 can include a connectorbottom portion edge 629. The connector 305 can include a connector endportion 350 and a connector back portion 344 (sometimes referred to asthe first connector back portion).

The connector top portion 618 can include a connector top aperture 519extending through the connector top portion 618. In an embodiment theconnector top aperture 519 aligns with the fastening feature 257. Theconnector top aperture 519 can be positioned between the connector topportion edge 619 and the connector end portion 350. The connector topaperture 519 can be positioned proximate to the concave edge 230.

The connector bottom portion 336 can include a connector bottom aperture529 extending through the connector bottom portion 336. In an embodimentthe connector bottom aperture 529 aligns with the fastening feature 257and can align with the connector top aperture 519. The connector bottomaperture 529 can be positioned between the connector bottom portion edge629 and the connector end portion 350. The connector bottom aperture 529can be positioned proximate to the concave edge 230.

The connector back portion 344 can include a first back portion 642 anda second back portion 644. The first back portion 642 can extend fromthe connector end portion 350 away from the connector bottom portion336. In other examples the first back portion 642 can extend from theconnector end portion 350 away from the connector top portion 319.

The second back portion 644 can extend from the first back portion 642.In an embodiment the second back portion 644 extend substantiallyperpendicular from the first back portion 642. In other example thesecond back portion 644 extends from the first back portion 642 atangles between perpendicular and parallel with respect to the first backportion 642.

The second back portion 644 can be oriented sustainably parallel withthe connector end portion 350. The first back portion 642, the secondback portion 644, and the connector end portion 350 can define and forma crown gap 650. The crown gap 650 can be sized to receive the base ofthe crown 410.

A mechanical fastener 296 can extend through the connector top aperture519 through the fastening feature 257 to through the connector bottomaperture 529 proximate the connector bottom portion edge 327. Themechanical fastener 296 can be used to connect the connector 305 to thevisor 217. The mechanical fastener 296 may comprise rivets, eyelets,sewing thread, screws, grommets, plastic inserts, and other commonfasteners.

FIG. 19 is a sectional view of an exemplary visor assembly. A visorassembly 207 can include the visor 218 and a connector 309. The visor218 can be thinner at the visor step 259 than away from the visor step259.

The connector 309 can include a connector bottom portion 625 that isdisposed adjacent the visor step 259. The connector bottom portion 625can include a connector bottom portion edge 628. The connector 309 caninclude a connector back portion 346 (sometimes referred to as the firstconnector back portion).

The connector bottom portion 625 can include a connector bottom aperture638 extending through the connector bottom portion 625. In an embodimentthe connector bottom aperture 638 aligns with the fastening feature 257.The connector bottom aperture 638 can be positioned between theconnector bottom portion edge 628 and the connector back portion 346.The connector bottom aperture 638 can be positioned proximate to theconcave edge 230.

The connector back portion 346 can extend sustainably perpendicular fromthe connector bottom portion 625 proximate the concave edge 230.

The connector back portion 346, the connector bottom portion 625, andthe concave edge 230 can define and form a crown gap 750. The crown gap750 can be sized to receive the bottom edge of the crown 410.

FIG. 20 is a sectional view of an exemplary visor assembly. A visorassembly 205 can include the visor 219 and a connector 307. The visor219 can include a visor top surface 227 opposite from the visor bottomsurface 247. The visor top surface 337 located at the top face of thevisor 219.

The visor 219 can be similar to visor 219 and can additionally include asecond visor step 258. The second visor step 258 can be similar to thevisor step 259 (sometimes referred to as the first visor step) andpositioned at the visor top surface 227. The second visor step 258 canbe substantially parallel with the first visor step 259.

The visor 219 can be thinner at the second visor step 258 and the firstvisor step 259 than away from the second visor step 258 and first visorstep 259.

The connector 307 can include a connector top portion 616 disposedadjacent the second visor step 258 and the visor top surface 227. Theconnector top portion 616 can include a connector top portion edge 617.The connector 307 can also include a connector bottom portion 623 thatis disposed adjacent the first visor step 259 and the visor bottomsurface 247. The connector bottom portion 623 can include a connectorbottom portion edge 626. The connector 307 can include a connector endportion 350 and a connector back portion 345 (sometimes referred to asthe first connector back portion).

The connector top portion 616 can include a connector top aperture 627extending through the connector top portion 616. In an embodiment theconnector top aperture 627 aligns with the fastening feature 257. Theconnector top aperture 627 can be positioned between the connector topportion edge 617 and the connector end portion 350. The connector topaperture 627 can be positioned proximate to the concave edge 230.

The connector bottom portion 623 can include a connector bottom aperture637 extending through the connector bottom portion 623. In an embodimentthe connector bottom aperture 637 aligns with the fastening feature 257and can align with the connector top aperture 627. The connector bottomaperture 637 can be positioned between the connector bottom portion edge626 and the connector back portion 345. The connector bottom aperture637 can be positioned proximate to the concave edge 230.

The connector back portion 345 can extend from the connector end portion350 away from the connector bottom portion 336.

The connector 307 can include a connector bottom portion 623 that isdisposed adjacent the visor step 259. The connector bottom portion 623can include a connector bottom portion edge 626. The connector 307 caninclude a connector back portion 345.

The connector bottom portion 623 can include a connector bottom aperture637 extending through the connector bottom portion 623. In an embodimentthe connector bottom aperture 637 aligns with the fastening feature 257.The connector bottom aperture 637 can be positioned between theconnector bottom portion edge 626 and the connector back portion 345.The connector bottom aperture 637 can be positioned proximate to theconcave edge 230.

The connector back portion 345 can extend sustainably perpendicular fromthe connector bottom portion 625 proximate the concave edge 230.

FIG. 21 is a sectional view of an exemplary visor assembly. A visorassembly 209 can include the visor 217 and a connector 500. Theconnector 500 can include a connector top portion 510 disposed adjacentthe visor top surface 220. The connector top portion 510 can include aconnector top portion edge 511. The connector 500 can also include aconnector bottom portion 520 that is disposed adjacent the visor bottomsurface 240. The connector bottom portion 520 can include a connectorbottom portion edge 521. The connector 500 can include a connector endportion 350 and a connector back portion 540 (sometimes referred to asthe first connector back portion).

The connector back portion 540 can extend from the connector end portion350 away from the connector top portion 510. In an embodiment theconnector back portion 540 extends substantially perpendicular from theconnector top portion 510 opposite from the connector top portion edge511.

INDUSTRIAL APPLICABILITY

The present disclosure generally applies to visor assemblies 200, 201,202, 203 204, 205, 206, 207, 208, 209, and cap assemblies 100, 101 withvisor assemblies 200, 201, 202, 203 204, 205, 206, 207, 208, 209.

There are couple common methods used in industry to connect visors tocrown assemblies to make caps and other headwear. The first commonmethod of uses a visor, made of plastic or cardboard, that is placedinto a fabric sleeve or pocket and creating a visor assembly having aportion where the fabric extends beyond the back of the visor to providea sewable medium to connect the cap crown and the sweatband to thevisor. This requires the visor to be covered with fabric and often timelimits the visor material to materials that can be easy sewn through andvisor shapes and materials that work well with a fabric sleeve/pocketover them. The second way involves using a visor made of sewablematerial. This allows the visor material to be visible, however thevisor materials are limited to materials that are sewable and have thestructural properties to endure a person wearing such a cap.

The connector back portion 340, 344, 345, 346, 347, 348, 540 can be madeof a sewable material and can be sewn with the crown 410 and thesweatband 450. The connectors 300, 302, 303, 304, 305, 306, 307, 308,309 can include features such as protrusions 332, 333, 334, 335,mechanical fasteners 295, 296, adhesives 290, 291, 292, and interfaces272, 273, 274 that can be configured to mate with and/or connect withvisors 210, 212, 214, 216, 217, 218, 219. The visors 210, 212, 214, 216,217, 218, 219 can include features such as fastening features 252, 254,256, 257, 258, 259 that facilitate the connection of the visors 210,212, 214, 216, 217, 218, 219 to the connectors 300, 302, 303, 304, 305,306, 307, 308, 309.

By incorporating the connectors 300, 302, 303, 304, 305, 306, 307, 308,309 a wider variety of caps with visors of different shapes andmaterials can be manufactured and used in cap assemblies. For examplematerials such as wood, metal, plastics, and composites such as carbonfiber could be used for visors 210, 212, 214, 216, 217, 218, 219.

Although this invention has been shown and described with respect todetailed embodiments thereof, it will be understood by those skilled inthe art that various changes in form and detail thereof may be madewithout departing from the spirit and scope of the claimed invention.Accordingly, the preceding detailed description is merely exemplary innature and is not intended to limit the invention or the application anduses of the invention. Furthermore, there is no intention to be bound byany theory presented in any preceding section. It is also understoodthat the illustrations may include exaggerated dimensions and graphicalrepresentation to better illustrate the referenced items shown, and arenot consider limiting unless expressly stated as such.

It will be understood that the benefits and advantages described abovemay relate to one embodiment or may relate to several embodiments.Aspects described in connection with one embodiment are intended to beable to be used with the other embodiments. Any explanation inconnection with one embodiment applies to similar features of the otherembodiments, and elements of multiple embodiments can be combined toform other embodiments. The embodiments are not limited to those thatsolve any or all of the stated problems or those that have any or all ofthe stated benefits and advantages.

What is claimed is:
 1. A visor assembly, the visor assembly comprising:a visor having a visor top surface, a visor bottom surface, a concaveedge extending between the visor top surface and the visor bottomsurface, the concave edge having a first end, and a second end oppositethe first end, and a front edge extending from adjacent the first end toadjacent the second end; and a connector having a connector top portionpositioned adjacent to the visor top surface, the connector top portionhaving a connector top portion edge located proximate to the concaveedge, the connector top portion edge extending from proximate the firstend to proximate the second end, a connector bottom portion positionedadjacent to the visor bottom surface and spaced from the connector topportion, the connector bottom portion having a connector bottom portionedge positioned proximate to the concave edge, the connector bottomportion edge extending from proximate the first end to proximate thesecond end, and a connector back portion extending from proximate theconcave edge and away from the front edge.
 2. The visor assembly fromclaim 1, wherein the visor assembly further comprises a connector endportion extending between the connector top portion and the connectorbottom portion and positioned adjacent to the concave edge.
 3. The visorassembly from claim 2, wherein the connector back portion extends fromadjacent the connector end portion.
 4. The visor assembly from claim 1,wherein the connector back portion extends from the connector bottomportion.
 5. The visor assembly from claim 1, wherein the connector topportion and the connector bottom portion substantially contour theconcave edge.
 6. The visor assembly from claim 1, wherein the visor hasa fastening feature located proximate to the concave edge.
 7. The visorassembly from claim 6, wherein the cap assembly further comprises amechanical fastener extending through the connector top portion, theconnector bottom portion, and the fastening feature.
 8. The visorassembly from claim 6, wherein the connector top portion furtherincludes a connector top protrusion extending from proximate theconnector top portion edge into the fastening feature.
 9. The visorassembly from claim 6, wherein the connector bottom portion furtherincludes a connector bottom protrusion extending from proximate theconnector bottom portion edge into the fastening feature.
 10. A capassembly, the cap assembly comprising: a crown; a visor having a visortop surface, a visor bottom surface, a first corner, a second corner, aconcave edge extending between the visor top surface and the visorbottom surface, the concave edge extending from the first corner to thesecond corner, and a front edge extending from adjacent the first cornerto adjacent the second corner; and a connector having a connector bottomportion positioned adjacent to the visor bottom surface, the connectorbottom portion having a connector bottom portion edge positionedproximate to the visor concave edge, the connector bottom portion edgeextending from proximate the first corner to proximate the secondcorner, and a first connector back portion extending from proximate theconcave edge to between the sweatband and the cap crown.
 11. The capassembly from claim 10, wherein the first connector back portion extendsfrom the connector bottom portion opposite from the connector bottomportion edge.
 12. The cap assembly from claim 10, wherein the connectorfurther comprises a connector top portion positioned adjacent to thevisor top surface, the connector top portion having a connector topportion edge positioned proximate to the concave edge.
 13. The capassembly from claim 12, wherein the connector further comprises a secondconnector back portion extending from proximate the connector topportion to between the sweatband and the cap crown.
 14. The cap assemblyfrom claim 12, wherein the connector further comprises a connector endportion extending from the connector top portion to the connector bottomportion and positioned adjacent to the concave edge.
 15. The capassembly from claim 14, wherein the first connector back portion extendsfrom the connector end portion.
 16. A cap assembly, the cap assemblycomprising: a crown; a visor having a visor top surface, a visor bottomsurface, a first corner, a second corner, a concave edge extendingbetween the visor top surface and the visor bottom surface, the concaveedge extending from the first corner to the second corner, and a frontedge extending from adjacent the first corner to the second corner; anda connector having a connector top portion positioned adjacent to thevisor top surface, a connector bottom portion positioned adjacent to thevisor bottom surface, a connector end portion extending from theconnector top portion to the connector bottom portion and positionedadjacent to the concave edge, and a connector back portion extendingfrom adjacent the connector end portion away from the concave edge. 17.The cap assembly from claim 16, wherein the visor has a fasteningfeature located proximate to the concave edge.
 18. The cap assembly fromclaim 17, wherein the cap assembly further comprises a mechanicalfastener extending through the connector top portion, the connectorbottom portion, and the fastening feature.
 19. The cap assembly fromclaim 17, wherein the connector top portion further includes a connectortop protrusion extending into the fastening feature and wherein theconnector bottom portion further includes a connector bottom protrusionextending into the fastening feature.
 20. The cap assembly from claim16, wherein the connector back portion further comprises a first backportion extending from the connector end portion, and a second backportion extending substantially perpendicular from the first backportion.